Pro Cast 20091 Releasenotes

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ProCAST 2009.1 Release Notes & Installation Guide

July 2009

CL/PRCA/09/01/00/A

ProCAST 2009.1

RELEASE NOTES & INSTALLATION GUIDE

The documents and related know-how herein provided by ESI Group subject to contractual conditions are to remain confidential. The CLIENT shall not disclose the documentation and/or related know-how in whole or in part to any third party

without the prior written permission of ESI Group.

© 2009 ESI Group. All rights reserved.

ProCAST 2009.1 i RELEASE NOTES & INSTALLATION GUIDE © 2009 ESI Group (released: Jul-09)

CONTENTS

CONTENTS

WHAT’S NEW 1 MeshCAST --------------------------------------------------------------------------------1 PreCAST-----------------------------------------------------------------------------------2

Mapping Tool-------------------------------------------------------------------------------- 2 Thermodynamic Databases ------------------------------------------------------------- 3

Solver ---------------------------------------------------------------------------------------5 Parallel Processing ------------------------------------------------------------------------ 5

Post-Processing--------------------------------------------------------------------------5 VisualCAST---------------------------------------------------------------------------------- 5

INSTALLATION GUIDE 7 Software Installation on Windows ---------------------------------------------------7

Installation of the Software--------------------------------------------------------------- 7 Installation of the License ---------------------------------------------------------------- 7

Software Installation on Linux ------------------------------------------------------ 11 Overview ----------------------------------------------------------------------------------- 11 CD-ROM Mounting Instructions ------------------------------------------------------ 12 Graphical Installation-------------------------------------------------------------------- 12 Installation of the License -------------------------------------------------------------- 16 Customization ----------------------------------------------------------------------------- 20

Getting Started ------------------------------------------------------------------------- 22 Starting the Software -------------------------------------------------------------------- 22 On-line Product Documentation ------------------------------------------------------ 22

AVAILABLE PLATFORMS AND PRE-REQUISITES 23 Product Availability -------------------------------------------------------------------- 23 Availability of the ProCAST DMP Version --------------------------------------- 25 General Requirements --------------------------------------------------------------- 26

SURVEY 27

ProCAST 2009.1 1 RELEASE NOTES & INSTALLATION GUIDE © 2009 ESI Group (released: Jul-09)

WHAT’S NEW MeshCAST

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This version is an update of version 2009.0 which corresponds to the first release of the new STL Mesh Generator. It also includes problems corrections and features improvements. For a complete list of the new or improved product functionalities, users are invited to consult the What’s New / Version 2009.1 section of the on-line product documentation.

MESHCAST

The Release of MeshCAST 2009.1 corresponds to the first release of a totally new surface mesh generator based upon STL files.

The goal of this STL surface mesh generator is to offer the possibility (in most cases) to generate meshes of single volume or assemblies in a fully automatic way.

Please note that in the above picture, the model is "exploded" for viewing purposes only and that the resulting surface mesh is a fully assembled mesh of the different components using single click STL SM application.

For more details, please refer to the "STL Mesh Generator" chapter of the MeshCAST 2009.1 Manual.

RELEASE NOTES & INSTALLATION GUIDE 2 ProCAST 2009.1 (released: Jul-09) © 2009 ESI Group

WHAT’S NEW PreCAST

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PRECAST

The following features have been added or improved:

- A new mapping tool is now available. It allows to extract Temperature, FVOL (filling information) and Porosity results from one calculation to an other, in the case where the two calculations were made with different meshes.

- New commands were added in the PreCAST Batch script (see the "Batch Pre-processing" section for more details).

Mapping Tool A mapping tool was developed as mesh definition depends on process modeling goal. For instance, to capture high thermal gradients of a heat treatment quenching step, the mesh has to be refined in the gradient direction at the surface of the part compared with the standard solidification and fluid flow modeling.

The principle of the mapping is the following for fields defined at nodes (like Temperature, FVOL or porosity): for each node of the target mesh, the corresponding element of the source mesh is searched. Then, the value of the target node is interpolated from the values of the vertices of the source element.

Warning: The mesh from which the results will be extracted must be in tetraedra only (it is not allowed to have hex or wedges). However the target mesh (i.e. the mesh on which the mapping will be applied) can have any type of elements.

The results mapping is working in the same way as the "Extract”.

The only difference is that one should select the "Mapping" button instead of the "Extract" one. All the rest of the procedure is identical.



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The two following images are showing the result of a mapping of an HPDC casting from a coarse mesh (left) to a fine mesh (right).

One can see that the match between the two meshes is very good. The quality of the mapping is as good when going from a fine mesh to a coarse one.

Thermodynamic Databases The following features have been added or improved:

- The Ni database was improved by the addition of Mn (up to 3%) and Cu. In addition, the quality of the calculations of the liquidus and of the gamma prime solvus were improved.

- The Fe database was improved in the case of alloys containing Nb (in conjunction with C).



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- The model for the calculation of the Yield stress of Al alloys was improved. Comparisons with experimental data are giving good results. Accordingly, the Yield stress of the "A356-Stress" and "A356-Visco-Stress" entries of the PreCAST database (stress.db) were modified to take into account this improvement. As the Yield stress is depending strongly on the microstructure, which is a result of different cooling rates, the A356-Stress single entry was replaced by four entries, which are valid for 4 typical cooling rates of 0.1, 1, 10 and 100 K/s.

The following figure is showing the calculated Yield Stress for an A356 aluminum alloy, cast under different cooling rates (and thus having different value of SDAS). One can see the very strong effect of the microstructure on the Yield Stress.

- The calculation of the Young's modulus of Cast iron was improved in order to take into account the influence of the graphite shape (i.e. for gray, compact or ductile iron). For this Young's modulus calculation, the effect of the graphite shape is triggered by the Mg content, according to the following amounts: Gray iron for Mg > 0.01%; Compact for 0.01% < Mg < 0.03%; Ductile iron for Mg > 0.03%.


WHAT’S NEW Solver

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The following features have been improved:

- The limitation of 10’000 steps in Radiation calculation has been removed.

- A problem in the reinitialisation of the displacement in the case of stress and cycling was corrected.

Parallel Processing Continuous efforts are being devoted to improve the scalability, repeatability and availability on various platforms of the ProCAST DMP solver. The following improvements have been made in ProCAST 2009.1:

- The THERMAL 2 option is now available in DMP.

- A problem of LPDC filling was corrected.

POST-PROCESSING

VisualCAST The main features of release 5.5 are mentioned in the list below: - The "Scale dialog box" (e.g. to change the temperature scale for instance) can be

opened automatically by a double-click on the scale.

- The liquidus and solidus are now displayed on the temperature scale. This display can be deactivated in the Scale dialog box (under Preferences - Datum Line)

- The plot of free surface information (like temperature, velocity ...) was improved.

- Improvements in the Exports are now available.

Please refer to the release notes of Visual Environment 5.5 under the section VisualCAST for the exhaustive list of improvements and new features.


INSTALLATION GUIDE Software Installation on Windows

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INSTALLATION GUIDE SOFTWARE INSTALLATION ON WINDOWS

Installation of the Software Insert the CD-ROM into the disc drive. Follow the procedure described below depending if autorun is enabled on your computer.

Autorun is enabled on your computer

The ProCAST installation should start automatically.

The InstallShield Wizard dialog box is displayed and then you should simply follow the instructions.

Autorun is disabled on your computer

Open a Windows Explorer window, click on your CD-ROM drive icon.

Double click on the Setup.exe file, located in the ProCAST20090_Windows directory, to start the software installation. The InstallShield Wizard dialog box is displayed and then you should simply follow the instructions.

When the software installation is completed, the ProCAST product will be available in the Start/Programs/ESI group menu or in the ESI Group icon folder on the desktop.

Installation of the License Before starting the license installation you should obtain a valid license file. Note that the ProCAST software is version protected and compiled with FLEXlm™ version 11.4. License files delivered for the previous ProCAST versions are not valid with this version of the software, except if your license does already contain the 2009 label.

System information must be retrieved before you can request your FLEXlm™ license files if required:

- For each PC machine that will be running ProCAST, execute c:\flexlm\lmtools.exe

- Select System Settings tab

- Send all the information on the left part (Hostid Settings) to your local ESI support representative with the “Save HOSTID Info to file” option.



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Once you have received your(s) license file(s), it/they must be moved to the appropriate directory c:\flexlm on each machine with the file name pam_lmd.lic.

Starting the FLEXlm™ License Server

The FLEXlm™ license server installation must be done with administrator privileges.

Once the ProCAST installation is completed, your pam_lmd.lic file must be moved to the appropriate directory, updated and the FLEXlm™ license server started. To move and update the license file:

- Move pam_lmd.lic to the directory c:\flexlm

- Using any usual text editor, edit pam_lmd.lic and change $PAMHOME to c:\flexlm\pam_lmd.exe on the line beginning with the DAEMON keyword

To start the license server:

- Execute c:\flexlm\lmtools.exe



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- Select the Service/License file tab and select Configuration using Services

- Select the Configure Services tab, adjust parameters as below and click the Save Service button



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- Select the Start/Stop/Reread tab and click the Start Server button

After completing these installation steps, you may start using ProCAST.

Additional specific FLEXlm™ documentation is also provided with the software on the installation CD-ROM.


INSTALLATION GUIDE Software Installation on Linux

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SOFTWARE INSTALLATION ON LINUX

Overview To install the ProCAST product on Linux platforms, two installation procedures are available:

- paminst-gui.sh graphical User Interface script,

- paminst.sh command line script.

Both procedures perform the following tasks:

1. Install the software :

· Copy from the CD-ROM all the software files to the chosen location.

2. License management :

· Install the license file,

· Start the license daemons lmgrd and pam_lmd if needed,

· Install the license daemon startup scripts*.

3. Customization :

· Set up the ESI Group software environment for each current user.

Tasks 2 and 3 can be performed later if the user does not want to do them immediately.

After the installation, the files installed on the hard disk are organized in a directory tree as indicated below:

Version1_COMMONRessource files

Version1_platformOS1Executables



MODULE 1Executables, other files...

MODULE 2Executables, other files...

ExamplesExamples files, test cases...

platformOS1Deamon and tool files

platformOS2Deamon and tool files

LICENSESLicense file

DOCElectronic documentation

Head Directorythis is referenced as PAMHOME

Installation Scripts...

* Sufficient privileges may be required by the system during the installation of ESI Software products. Although no system library is updated in the process, sufficient privileges will be needed to mount the CD-ROM and to install the boot files to start the license server.



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CD-ROM Mounting Instructions Insert the CD-ROM into the CD-ROM drive.

Follow the CD mounting and dismounting instructions in the table below.

When the installation is done, don’t forget to quit the directory /cdrom before ejecting the CD-ROM from the drive.

PLATFORM MOUNTING SPECIFIC INSTRUCTIONS DISMOUNTING

PC Windows Automatic - -

PC Linux Automatic - eject

# symbol is the SCSI Id number of the CD-ROM drive Device names in italics are site dependent

Graphical Installation

System requirement:

The installation through graphical user interface is available on Linux. In order to use the graphical installation, you need a X compliant window system available on your display. You must position the DISPLAY environment variable for display on the current screen, and if necessary allow this display using an appropriate xhost command on the display host. You also need about 5 Mb of free space in /tmp, in order to store graphical tools temporarily.

To start the graphical software installation script, go to the /cdrom directory then type the following command:

./install.sh To complete the installation follow the instructions displayed in blue colour in the dialog boxes presented by the installation tool.

After the graphical tools are loaded in /tmp, the main dialog box window appears:



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Main Dialog Box Window

Click the Install software button. It will highlight the Next button to continue.

Click the Next button to continue the software installation.

Click the Cancel button to abort/exit the software installation.



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Installation directory dialog box window

This dialog box is used to specify the installation directory.

By default, the text field of the installation directory is filled with the previous pathname of ESI Group software installation directory if any.

Two possibilities are available to select a new software installation location on the system:

- Click on and fill the text field with a valid pathname directory (read, write, execute permissions are required),

or

- Click the Browse button to select another software installation location (see Directory selector dialog box for using it).

Click the Next button when you are satisfied with the software installation directory selected.

Click the Previous button to go back to the main dialog box of the software installation.



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Package Selection:

Package Selection Window

This dialog box is used to select all the software package(s).

Select all the platform package(s) you wish to download on the system by clicking on the toggle(s) then click the Next button to continue. Note that, if not already done, the flexnet_v10.1.3 package should also be installed for all platforms.

A scrolled window is displayed showing the downloading of files.

When the downloading is finished, the Close button will be highlighted.

Click Close to continue.



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The main dialog box window appears again to perform the next steps, the license installation and/or Customization of the software environment.

Click the Exit button if you wish to perform the License installation and software customization later.

Click the License management button to install the license. A license file is needed to perform this task. For more detail, please and see the Installation of the license section.

Click the Define environment button to customize the software environment. For more detail, please see the Customization section.

Installation of the License Before starting the license installation you should copy the new or updated FLEXlm™ license file provided by ESI Group representatives in the following directory PAMHOME/licenses with the filename PAM_LICENSE.temp.

Note that the ProCAST software is version protected and compiled with FLEXlm™ version 11.4.0. License files delivered for the previous ProCAST versions are not valid with this version of the software, except if your license does already contain the 2009 label.

The installation of the license should be performed on the system where the license server will run. To start the graphical license installation script, go to the software installation directory and type the following command:



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./paminst-gui.sh lic or ./paminst-gui.sh install_lic After the graphical tools are loaded in /tmp, the following assistant window appears:

Follow the instructions displayed in blue colour.

Get host id. Button

Click the Get host id button to get the information (hostname, hostid) of the system needed for license server installation (floating license) or standalone license (node-locked license). It will display the following window:

License directory selection:

By default, the Install licenses directory under directory: text field is filled with the pathname of the previous software installation directory.

Click the Browse button to redefine the pathname of the software installation directory. Note:

· The specified directory in the text field should contain a licenses subdirectory with write permission to highlight the Next button.



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Click the Next button when the installation directory pathname is selected. The license file is installed in the right location and the following dialog box appears:

Click the Get another license file button to select a new license file.

Click the OK button to find the new license file on the local disk. A new file browser window appears.

By default the file filter is set for find PAM license file. Select the new license file then click the Open button to validate the selection.



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A small window pops up displaying the checking result of the selected license file with the host id.

The dialog box of license file selection will be displayed again and filled with information corresponding to the selected license file.

Click the Save new file as current button. The new license file is installed and the Next button is activated to continue.

Click the Next button to start the license daemons.



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Click the Start daemon now as current user button to start the daemon.

Additional specific FLEXlm™ documentation is also provided with the software on the installation CD-ROM.

Customization The ESI Group software installation script paminst.sh can be used for customization. This customization is done with pamcust.sh which can also be used separately. To perform the customization separately:

- Log in on the machine on which you want to perform the customizations,

- Change directory to the $PAMHOME directory where the installation has been done,

- Type ./pamcust.sh and follow the instructions.

The customization script creates definitions to allow access to the ProCAST executables and configuration files for all users or for selected users, depending on the method selected. The software configuration is defined in the following files:

- psi.Cenv for csh and derivatives,

- psi.Kenv for ksh and derivatives,

- Psi.Baenv for bash.



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Note that sh is not supported due to its lack of functionalities necessary for ESI Group products. We recommend sh users to migrate to ksh which preserves sh syntax and habits.

The customization procedure will automatically update the .cshrc, .profile or .bash_profile files accordingly, as shown below.

C Shell - .cshrc file ### PAM-SYSTEM begin ### # # PAM-SYSTEM Software environment # setenv PAMHOME /usr/people/test setenv PAMENV $PAMHOME/env-‘uname’ if ( -r $PAMENV/psi.Cenv ) then source $PAMENV/psi.Cenv endif ### PAM-SYSTEM end ###

Korn Shell - .profile ### PAM-SYSTEM begin ### # # PAM-SYSTEM Software environment # PAMHOME=/usr/people/test; export PAMHOME PAMENV=$PAMHOME/env-‘uname’; export PAMENV if [ -r $PAMENV/psi.Cenv ]; then . $PAMENV/psi.Kenv fi ENV=${ENV:””} If [ -z “$ENV” ]; then ENV=$HOME/.kshrc; export ENV fi ### PAM-SYSTEM end ###

Bourne Again Shell - .bash_profile

### PAM-SYSTEM begin ### # # PAM-SYSTEM Software environment # PAMHOME=/usr/people/test; export PAMHOME PAMENV=$PAMHOME/env-‘uname’; export PAMENV if [ -r $PAMENV/psi.Cenv ]; then . $PAMENV/psi.Kenv fi BASH_ENV=${BASH_ENV:-””} If [ -z “$BASH_ENV” ]; then ENV=$HOME/.bashrc; export BASH_ENV fi ### PAM-SYSTEM end ###

The same procedure must be repeated for the customization of each candidate user.


INSTALLATION GUIDE Getting Started

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GETTING STARTED

Starting the Software

For Windows platforms:

When the software is installed on Windows, a file folder named ESI GROUP is automatically created on the computer Desktop. Inside this folder, a "ProCAST 2009.1 Manager" icon is present. A double click on the corresponding icon will automatically start the software manager and give access to different product modules.

For Linux platforms:

The installation procedure includes a customization procedure. The customization script creates definitions to allow access to the different executables and configuration files for all users or for selected users, depending on the method chosen.

After a complete and successful product installation, necessary environment variables and aliases are automatically defined to start different product modules. Type the following commands for a direct access:

- cast for the software manager,

- meshcast for the mesh generator,

- precast for the pre-processor,

- datacast and procast for the solvers,

- viewcast for the post-processor,

- vcast for the new post-processor VisualCAST.

Note that access to previous versions of ProCAST is possible with modified aliases. For instance, type cast090 for the ProCAST 2009.0 software manager.

On-line Product Documentation On-line product documentation is available for most ProCAST features. Two manuals are provided with the standard installation: the MeshCAST User Manual and the ProCAST User manual. These User Manuals provide extensive information to guide users through the different modules of ProCAST, to explain the use of different software features as well as to give technical information on models and algorithms.

Refer to the User Manual and in particular to the What’s New / Version 2009.1 section for detailed information on all new and improved product features.


AVAILABLE PLATFORMS AND PRE-REQUISITES Product Availability

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AVAILABLE PLATFORMS AND PRE-REQUISITES PRODUCT AVAILABILITY

ProCAST has currently been tested and validated on the following hardware platforms: Solver:

Vendor Processor OS Memory addressing

DMP

Intel Windows 2003 Windows XP Windows Vista

32 bits yes Windows

Intel / AMD Windows 2003 x64 Windows XP x64 Windows Vista x64

64 bits yes

Intel Redhat 9.0 (compatible) Redhat EL3 and higher

32 bits yes Linux

Intel / AMD Redhat EL3 and higher

64 bits yes

User Interfaces:


Windows Intel / AMD Windows 2003 Windows XP Windows Vista

32 bits

Linux Intel / AMD Redhat 9.0 (compatible) Redhat EL3 and higher

32 bits

Remarks:

· Specific MeshCAST executables are available for 32 and 64bits platforms. The Parasolid interface is only available on 32bits platforms.


AVAILABLE PLATFORMS AND PRE-REQUISITES Product Availability

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VisualCAST:


Intel Windows 2003 Windows XP Windows Vista

32 bits Windows

Intel / AMD Windows 2003 x64Windows XP x64 Windows Vista x64

64 bits

Intel Redhat EL3 Suse 9

32 bits Linux

Intel / AMD Redhat EL4 Suse 10

64 bits

Refer to the Visual Environment product documentation and in particular to the VisualEnvironment-5.5_InstallationGuide.pdf document for detailed information on hardware requirements.

Remarks:

· The ProCAST 2009.1 package requires the installation of the VisualCAST 5.5 version.


AVAILABLE PLATFORMS AND PRE-REQUISITES Availability of the ProCAST DMP Version

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AVAILABILITY OF THE ProCAST DMP VERSION

The ProCAST DMP version is included on the installation CD-ROM.

The standard DMP parallel version of ProCAST is currently available on

- Linux 32 bits Redhat Entreprise Linux 3 using HPMPI, PETSc and ParMetis libraries (Linux kernel above 2.4.21 and glibc version above 2.3.2),

- Linux 64 bits Redhat Entreprise Linux 3 using HPMPI, PETSc and ParMetis libraries (Linux kernel above 2.4.21 and glibc version above 2.3.2),

- Windows XP and VISTA using HPMPI, PETSc and Parametis libraries.

The HPMPI: Message Passing Interface version 2.2.5 on Linux and version 1.1 on Windows (copyright HP) are used and required runtime libraries are included in the software package.

The PETSc: Portable, Extensible Toolkit for Scientific Computation (Copyright 1995-2004, University of Chicago) version 3.0.0. is used on all platforms and required runtime libraries are included in the software package when appropriate.

The ParMetis version 3.1.1 is used on all platforms for dynamic domain partitioning and required runtime libraries are included in the software package when appropriate.

Specific parallel executables are also available upon request for the following hardware platforms:

- Linux 64 bits IA-64 Itanium Redhat Linux Advanced Workstation 2.1 using HPMPI, PETSc and ParMetis libraries (Linux kernel above 2.4.18).

For additional information, refer to the User Manual and in particular to the Parallel solver / Use of the parallel solver section for a detailed description of the necessary commands.


AVAILABLE PLATFORMS AND PRE-REQUISITES General Requirements

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GENERAL REQUIREMENTS

In the list below, some global recommendations are given for running ProCAST on the various platforms. Please consult with the local ESI Group support for more information.

A minimum of 2 Gb of memory is required to operate the software. More memory is however recommended for large industrial applications.

Consult the information provided in the installation directory $PAMHOME/info/README_ProCAST_2009.1 for a complete list of run time libraries and pre-requisites corresponding to each platform.

For access to on-line documentation, Mozilla (or equivalent) is required on all Linux platforms.

OpenGL hardware graphic accelerator is highly recommended. Screen resolution should be set to at least 1280*1024 with small fonts selected.

For optimal graphics performance on Windows platforms, the installation of the latest graphics drivers is recommended.

3 button mouse is required (middle mouse button required for dynamic rotations in graphics window with VisualCAST).

ProCAST 2009.1 requires the installation of the VisualCAST 5.5 version.

On Linux and Windows platforms, the icc compiler version 11.0 is used for the solver compilation.

To compile User functions, the following compilers should be available on the target platform:

- Windows : Microsoft Visual C++ 2008 Express Edition (free of cost as of February 2009)

- Linux : Intel icc compiler version 11.0 or gcc compiler version 3.2.3


SURVEY

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SURVEY The information you will provide is of highest value for us in order to better understand your expectations and to enhance our services. Therefore, we warmly thank you in advance for the time and assiduous attention you will devote to filling in this form and for sending it back by fax (+41 21 693 4740), post mail to Marco Aloe / Calcom ESI / Parc Scientifique EPFL / PSE-A / CH-1015 Lausanne / Switzerland or by email to [email protected].

1 GENERAL INFORMATION Your data :

1.1 Name of the company

1.2 Field of activity

1.3 Department or service

1.4 Address 1

1.5 Address 2

1.6 Your first and last name

1.7 Your title or function

1.8 Your direct phone and fax

1.9 E-mail

2 INFORMATION ON THE PRODUCT FEATURES

2.1 Operating system (Windows, Linux, other…)

2.2 How long have you been using this product?

2.3 How many people are using this product?


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Your assessment :

3 PERFORMANCE OF THE PRODUCT Uns

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3.1 Meshing time from CAD import

3.2 Pre-processing effectiveness / relevancy

3.3 Simulation time

3.4 Solver stability :

3.4.1 thermal simulation

3.4.2 fluid-flow simulation

3.4.3 stress simulation

3.4.4 ………… simulation (***)

3.4.5 ………… simulation (***)

3.5 Accuracy and relevancy of the results according to each feature :

3.5.1 thermal simulation

3.5.2 fluid-flow simulation

3.5.3 stress simulation

3.5.4 ………… simulation (***)

3.5.5 ………… simulation (***)

3.6 Post-processing effectiveness and relevancy

3.7 General graphic rendering of software

3.8 User-friendliness, comprehensibility, ease of navigation in menus

3.9 User manual, release notes

(***) Please mention the additional simulation features, if any, you work with


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Your assessment :

4 PERFORMANCE OF THE RELATED SERVICES Uns

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4.1 Frequency of product’s delivery (CD-ROM and accessories)

4.2 Packaging of the delivered product (CD-ROM and accessories)

4.3 Ease of installation

4.4 License key delivery

4.5 Answer’s accuracy of our hot line (with respect to software)

4.6 Answer’s quickness of our hot line (with respect to software)

4.7 Training quality

4.8 Commercial follow-up

4.9 Overall assessment

5 EVOLUTION OF THE PRODUCT

5.1 Simulation’s accuracy

5.2 CPU time

5.3 Software stability

5.4 Number of functionalities

5.5 Graphical User Interface (GUI)

Please circle the arrow corresponding to the evolution of the product you have observed over the last years.

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